Artificial breast



Oct. 3, 1950 J. P. BORDNER ARTIFICIAL BREAST 3 Sheets-Sheet 1 FiledMarch 11, 1946 m R N MM I R 0 B P S E w d ATTORNEY.

3 Sheets-Sheet 2 Oct. 3, 1950 Fil ed March 11, 1946 INVENTOR. damn I?Bonn/van.

A T TORNEY.

0a s, 1950 J, P, BQ NER 2,524,028

ARTIFICIAL BREAST Filed March 11, 1946 3 Sheets-Sheet 3 so es IN V ENTOR. JAMES P .BORDNER.

flTTo A/EK Patented Oct. 3, 1950 ARTIFICIAL BREAST James P. Bordner,Burbank, Calif.,

assignor, by

mesne assignments, to Forms Incorporated, a corporation of CaliforniaApplication March 11, 1946, Serial N 0. 653,665

2 Claims.

The invention relates to artificial breasts and breast pads designed toretain the full molded symmetry of a female breast and at the same timepreserve a naturalness of texture and form so that the resultant efiectwill be realistic.

Although arificial breast fronts and bust pads have been in common usefor a great many years and although they have been designed andmanufactured in a form intended to simulate the form of a female breast,for the most part the form has been no more than an approximationdesigned to serve as a foundation over which garments might be draped togive the garment sufiicient support to convey the impression of therebeing a breast of appropriate proportions therebeneath.

Furthermore, the various artificial breasts in common use are of suchinner contour that instead of the pad conforming to the breast, thebreast must conform to the pad. Consequently, when worn the pad presssesagainst the nipple and flattens the nipple together with the aureolewhich is definitely unhygienic and harmful.

Insufficient attention has been given to the design and preparation of abreast foundation front representing a real breast with sufiicientveracity so that it could be worn under very light-weight or abbreviatedgowns. To be truly effective the breast foundation front must avoid theappearance, under these circumstances, of being an obvious false frontor a built-up foundation.

It is, therefore, among'the objects of the invention to provide a newand improved artificial breast front fitting, light in weight and of asufficiently firm texture so as to give a realistic impression and atthe same time to make the front capable of being worn with comfort.

Another object of the invention is to provide a breast foundation frontadapted to fit the breast in the nature of a brassire so that inaddition to providing a built-up front the breast beneath it will besupported and strengthened to a desirable degree.

Still another object is to provide a new and improved breast front sofitted to the contour of the bust that the outline of the breast frontwill snugly fit the bust with the majority of pressure againstthepectoral muscles upon which the breasts depend for support so that anymovement in the ordinary course of wear will have the effect ofmassaging the pectoral muscles and thereby permit the user to enjoy ahygienic and beneficial effect.

Still another object is to provide an artificial breast foundation frontwhich can be so arranged as to lift the breast and utilize a portion ofthe wearers breast supplemented by the foundation to give the appearanceof an up-lifted breast of more generous proportions and erect form thanis actually present.

It will be apparent from the accompanying drawings and the followingdescription that while many elements of the structure and the methodherein described for producing the structure are familiar to the art ofmaking foundation fronts, old elements and new have been marshalledtogether to produce a new and novel artificial front entirely distinctfrom anything heretofore used or produced, easy to fabricate andoperate,more efficient than previous methods and products produced thereby, andhaving a usefulness which will continue indefinitely.

In the drawings which'illustrate-the steps of the method and the productproduced thereby:

Figure 1 represents a perspective view showing the first step of themethod where the original impression is made on a human model form.

Figure 2 represents a perspective view showing successive steps in theapplication of material to the human form.

Figure 3 is a cross-sectional view showing a composite structureresulting from further steps in the product of the front.

, Figure 4 is a cross-sectional view of a molded reproduction of thebreasts illustrated in Figure 1.

Figure 5 is a cross-sectional view of one of the breasts shown in Figure4 broken away from the other.

Figure 6 is a rear view of the form shown in Figure 5 taken on the line6-6.

Figure 7 is a longitudinal,.sectional view of the form shown in Figure 5taken on the line l'l.

Figure 8 is a sectional view of the form in place in a mold box showingan intermediate step in the production of a master cavity mold.

Figure 9 is a sectional view of another mold box in which a casting coreform has been poured.

Figure 10 is a sectional view of the mold box featuring anotherintermediate step in preparation of a master cavity mold.

Figure 11 is a sectional view of a mold box wherein material has beenpoured around the casting core to form the permanent cavity mold.

Figure 12 is a cross-sectional view showing the first steps in theproduction of a permanent male mold or form for use with the permanentcavity mold.

Figure 13 is a longitudinal, sectional view of a mold box illustratingthe final step in the production of a permanent male mold for use withthe permanent cavity mold.

' 3 Figure 14 is a sectional view of the permanent cavity mold and malemold during the process of casting an article of the nature of a falsebreast front.

Figure 15 is a longitudinal, sectional view showing a resulting falsebreast front made by the process.

Figure 16 is a fragmentary. sectional view of the resulting productincorporating certain appurtenances.

Figure 17 is a front, perspective view partially broken awayillustrating the first steps of the method modified in a specifieddegree.

Figure 18 is a profile view partially in section showing the applicationof a pad of modified form to the breast of a wearer.

Figure 19 is a perspective side view of a "pad of modified form.

Figure 20 is a front elevational view of the pad shown in Figure '19.

There is a commonly accepted and wide-spread practice among women to useartificial breast fronts as a foundation in dressing so as to give thebreasts a full fashioned roundness and uplifted eifect in order thatclothes may hang propany and to generally enhance the figure. withchanging modes of dress in which undergarments have been considerablyabbreviated there is an increasing demand for realism of form so thatif.

bust pads are to be used they must simulate to the closest possibleextent the form, character andtexture of real breasts. Inasmuch as thetendency is to enlarge the appearance of breasts to a degree more orless depending upon the form of the wearer, enlargedbreast forms mustbecapable of application to the wearer in a manner which will permit themto be worn comfortably over relatively long periods of time, which willpermit them to look real when in place on the bust, and which will, inaddition, give to the wearer the help and support normally expected of awell-fitting brassire.

Where possible, it is desirable to have the artificial breast frontsimpart, in addition, a hygienic and beneficial effect, the value ofwhich will continue to be enjoyed after the fronts have been removed. Tosatisfy these demands the' fronts or forms must have the full moldedsymmetry of female breasts of generous proportions incorporating all thedetails of the natural physical form.

In order to build a pad of the desired form and proportions, a real-lifemodel is selected having the form and proportions desired. To both nudebreasts of the model is applied a material Hi commonly known by thecommercial designation as mulage or moulage which is a plastic materialused to a considerable extent for making masks for various purposes, andwhich has the quality of adapting itself to the form which is to bemodeled without sticking to the surface of the form, either in themoistened or hardened state, and without it being necessary to apply alubricant to the surface to be copied.

Mulage is commonly known to incorporate the ingredients ofagar-granular, sodium benzoate, U. S. P. glycerine and water pre-mixedin proportions which produce a material having the unusual faculty ofabsorbing and retaining moisture and of jelling rapidly and firmly. Itis of such a harmless character that it may be eaten or poured on themost delicate membrane without any harmful effect. It will not adhere toany article and may even be poured on the human posite structure willhave a sufllcient amount of physical strength when removed to avoidbeing easily broken.

It is importantto note that during the foregoing steps in the processthe mulage will be pressed snugly about the model form, particularlyalong the line of demarcation or junction of the breast contours withthe bust or chest, and that v the line and contour at the juncion willbe preserved, reinforced and stiffened by the application of plaster ofParis to the mulage over these areas. The effect will be to produce arim designated by the character it which follows the line of junction ofthe breast with the surface of the chest or bust. The line of junctionwill have not only the outline-of the line of junction or demarcationbut will also conform to the variations of the body formation.

After the plaster of Paris has hardened, the composite structure isremoved from the model form. The structure will then have preservedtherein a pair of cavities or recesses l5, it which will be thecomplement of the original model form in all of'its details. To thewalls of the cavity will be applied a layer of wax i1 over the entirearea. The wax layer should preferably be of substantial depth. Inpractice a satisfactory depth has been found to be in the neighborhoodof of an inch, but this may be varied an amount either way dependingupon particular conditions which may be experienced in the building upof the structure, these-being in part the result of variations in thetypes of material used or the wetness of, the ingredients. In any event,the area .of contact between the wax and the mulage will correspond inlocation, form and contour to the skin surface of the model.

After the wax has been applied and permitted to harden, the cavity orrecess defined by the wax will be filled with a mass or core IQ ofplaster of Paris of a suitable texture, care being taken to form theupper surface IQ of the plaster of Paris core with a depression 22 atthe center of each side so that the surface I! over all of its area liesbelow the rim ll. After the plaster of Paris core has hardened, the corewill cling to the wax, and the core together with the wax maybeseparated from the composite structure defined jointly by the layer ofmulage and on the exterior by the plaster of Paris layer l3. Since it isthe character of mulage not to adhere to any adjacent surface, it willremain free from the layer of wax which is painted over it and thuspermit ready removal.

Upon removal, the plaster core i8 bearing the wax surface I! will have aform in cross-section as illustrated in Figure 4, being joined togetherat the area 20. It is then preferable to break the sections apart at thearea 20 and treat with each section individually to make a separate moldfor each. It should be noted in this connection that the core togetherwith the wax surface will have a rim or edge 2i which will follow theform of the rim M in line and depth and that the rim 2| will present asomewhat wavy appearance as evident particularly in Figure 5. The rim 2|can be made to take this form by smoothing out the edge of the wax andthe plaster of Paris core l8 around and adjacent the rim l4 when the waxand plaster of Paris are applied to the mold cavities, as shownparticularly in Figure 3.

The form shown in Figures 5, 6 and 7 will represent the precise form ofthe model so that not only will a general breast area 22 and nipple 23be reproduced but also the true line of junction defined by the rim 2|between the breast and the bust, the outline of which is particularlyapparent in Figure 6.

The form comprising the core l8 and wax layer l1 constitutes a masterform of permanent character. It is next necessary to prepare from thismaster form a mold cavity from which a duplicate working mold can becast. To this end a sheet 25 of some material such as sheet lead will bepressed against the rear face of the master form and in particularpressed against the rim 2| so that the lead will follow the contour andshape of the rim. The lead and the master form will then be placed onthe bottom of a mold box 26, as shown in Figure 8, and screws or pegs 21inserted through the sheet lead so that they will eventually key thesheet lead to a mass 28 of plaster material which may then be pouredinto the box. The mass 28 of material may again be plaster of Parissince this material in particular has the capacity of closely followingthe surface being molded without substantial variation. The mass 28 ofplaster of Paris may then be removed from the box 26, the screws or pegs21 removed so as to permit removal of the sheet lead, and then themaster form comprising the core [8 and wax layer I! may be removed.

After the core and wax layer have been removed, the sheet lead will bereplaced by use of larger screws 21', and the mass 28 of plaster ofParis comprising a cavity mold will then incorporate a mold cavity 29which will have the true shape of the master form which in turn embodiesthe shape of the original model. The mass 28 of plaster of Paris willthen be inverted within a mold mox 30, the sides of which are higherthan the sides of the plaster of Paris material. Apertures are .thenmade in the sheet lead into one of which is inserted a pouring tube 3|and into the other a vent tube 32. Following this the space between thetop surface of the sheet lead 25 and the top of the side walls of themold box 30 may be filled with sand 33 and a lid 34 applied to the topof the box to hold and press the sand into place. As shown in Figure 9,clamps 35 may be used engaging the lid and blocks 36 on the box walls tofasten the lid.

After these parts have been assembled, a casting material such, forexample, as the commonly known hydrocal, is poured through the tube 3|until it fills the cavity 29, air being meanwhile vented through thetube 32. As a result there is formed a mold core 40 or duplicate moldwhich will set up hard and be of such property that it may be placed incontact with material of the character of molten metal and still retainits original shape and form. Although hydrocal has been suggested, othermolding materials of a similar composition commonly known to the art maybe employed.

After the mold core 40 has set, the lid 34 is removed, the sand 33 ispoured out, and the lead sheet removed by release of the screws or pegs21'. Removal will expose an upper surface 4| of the mold core 40and/also an upper surface 42 of the plaster of Paris mass 28. It will beapparent that the line and contour of the surface 42 will be the same asthe line and contour desired of the breast front which will eventuallybe formed from the mold inasmuch as this surface will have been made toform to the original line and contour of the model.

To facilitate subsequent use of the mold, pins 43 may be applied to theholes left by the screws 21', the surfaces 4| and 42 painted with alubricant or investment, and then a layer 44 of hydrocal, or similarmaterial, poured and finished off with a smooth, flat surface 45.

The several masses of material will then be removed from the box 30. Themass 28 of plaster of Paris will be broken away from the mold core 40,and the mold core together with the layer 44 of similar material will beinverted and placed in the bottom of a box mold 46 of proportionssimilar to the box 30. The last described box, however, must be of amaterial into which molten metal may be poured without resulting damage.After the cavity mold 28 and layer 44 have been fixed within the boxmold 46, as shown in Figure 11, a mass of molten metal, or other plasticmaterial capable of forming a permanent, lasting mold, will be pouredinto place surrounding the core and permitted to set. When the metal hasfinally set and cooled, it can be removed from the box 46 and the layer44 and mold core 29 removed. The metal will then provide a permanentfemale mold portion 50 or cavity mold having a mold cavity 5| which isthe complement of the exterior surface of the original model.

By the foregoing process there is defined onehalf of a set of permanentmolds from which the artificial breast can be cast. The next step is toprovide a second mold part for use with the first 4 which will provide abreast pocketin the breast front in order that the front may be fittedto a wearer. I

The second mold part will be male form and presumably made tosubstantially the size of the breast of the prospective wearer. It isanticipated, however, that a certain predetermined variety of sizes maybe provided since it is not essential to have a tailored fit in eachcase. To this end a model breast 41 is selected of a size and shaperelativel smaller than the original model illustrated in Figure 'l.

A temporary mold is made of the breast following the same proceduredescribed in connection With Figures 1 and 2, utilizing a layer ll) ofmulage, a layer ll of plaster of Paris, strips I2 and an outer plasterof Paris layer I3. The succeeding described steps will also be followedin the same sequence until there has been formed a temporary moldsimilar to the wax coated core illustrated in Figure '7. Since it isdesired to produce a metal or permanent mold having precisely the sameshape and size as the wax coated core, the next step incorporates theapplication of a sheet of lead to the core of smaller size in the samemanner as previously described and then insertion of the smaller coretogether with the lead sheet in a box mold. The box will have the samegeneral shape and size illustrated in Figure 8 or slightly smaller.

On this occasion, however, instead of pouring a material such as plasterof Paris into the box mold around 'the core a material such as thepreviously described hydrocal is used making a cavity mold 55.

7 In preparing the cavity mold ii for the next step, illustrated inFigure 13, the procedure described in connection with Figure 9 may befollowed to a certain degree. That is to say, the

cavity mold I! may be placed in a suitable box mold it initially withthe cavity uppermost and the core still in place. On this occasion,however, it may be advisable to immediately fill the remaining upperportion of the box with a layer II of hydrocal. To prevent the layer llof hydrocal sticking to the core and the cavity mold ll, exposedsurfaces may be painted with a lubricant or investment such as, forexample, turpentine, which forms a definite separating line which willpermit the layer 61 when set to be lifted from its position over thecore and cavity mold 56.

In performing the next step the layer 51 will in fact be removedtemporarily, the wax coated core will also be removed, and the layer 51replaced. A preferred practice. however, is to remove the cavity mold 55also from the mold box. place the cavity mold and layer 51 together,invert them, and place them within the box mold 56 in the positionsillustrated in Figure 13.

Molten metal may then be: introduced into the cavity within the cavitymold 55 through a suitable tube 58. In this instance, since the pouringtube extends upwardly into the pouring cavity, molten metal will need tobe introduced under pressure. Likewise in this instance, vents not shownbut familiar to those skilled in the art of casting materials, may beemployed.

After the metal has set, the mold may be broken apart and a permanent,metal, male mold part is removed.

The mold parts are now ready for assembly in v the manner illustrated inFigure 14. As there shown, "the cavity mold part 50 will be placed inposition with the cavity uppermost within a frame defined by uprightelments 80 and a crosspiece or platen 6 l It will be desirable to havethe male, permanent, mold part 59 attached in proper position to theunderside of the platen 61, the

platen being in turn attached to a piston rod 62 for moving it up anddown. The mold parts will then be adjusted to the positions shown inFigure 14, and foam rubber or sponge plastic material of a suitablformula or mix passed through a feeder tube 83 into the space formedbetween the two mold parts. A vent tube 64 is provided for the readyescape of air which may be present in the space between the two moldparts.

The foam rubber or plastic material will be forced into the space untila mass of the material completely fills out all portions of the space.After the mass has been cured or permitted to coagulate and solidify toa desired amount so that it will all adhere together as an integralmass, the molded parts are separated, and a full molded, artificialbreast member 65 will be removed. This may be a left breast or a rightbreast member depending upon which of the two parts have been molded. Toconform with the realistic efiect desired, both left and right breastswill be molded separately so that they may be matched as a pair andconform more closely to the original model.

To further the use and application of the false breasts, fabric tabs 65extending into the member may be molded in place during the moldingoperation. As a result, these tabs will be firmly implanted in thematerial of the resulting product and will facilitate sewing the falsebreast members to the inside of a brassiere, bathing suit or othergarment. It will be apparent that the false breast has an exteriorsurface 01 which truly and correctly resembles and simulates theexterior surface of the original model. The false breast will likewisehave a breast pocket 68 which corresponds in shape and size to thebreast of the prospective wearer. To increase ease and comfort whilewearing the false breasts, the breast pocket 68 may have applied theretoa fiocculent material 69 which may be applied by spraying or blowing itagainst a coating of liquid latex or other suitable adhesive. It isimportant, also, to note that the false breast will have a rim 10 which,because of the molding process just described, will have the outline anddepth of configuration of the bust or chest of th wearer-at the line ofjunction with the breast, or sufllciently so to permit the rim to restsnugly upon the pectoral muscles which surround each breast. Applicationof the rim lightly, but firmly, to these muscles will effect a massagingaction whenever the false breasts move about in the ordinary course ofwear.

It is, of course, highly advantageous to give the artificial breastmembers a proper tint or color. Depending on circumstances, the tintingmay be of one of a variety of different flesh colors, or, if desired,the color may be ligh or dark to blend with a garment which may be wornover the members.

on some occasions where an original model of the precise style and sizecannot be procured or where a different size or type of false breast maybe desired, the model may be supplied with a form-fitting brassiere 15which will uplift and shape the model's breasts. After this has beendone, the same sequence of steps originally described in connection withFigures 1 through 11 may be again followed as may also the stepsdescribing the making of a male mold part corresponding to the breastsof the prospective wearer. The mulage may b applied directly over thebrassiere, and after the modeling has been completed, the brassiere maybe readily removed from its contact with the mulage.

On other occasions it may be desired to re- 'form the contour of thebreast of the wearer and to supplement it with a pad or uplift whichdoes not entirely cover the breast. One means of accomplishing this isto make a cavity mold similar to the mold 50 and then a male, permanentmold similar to the mold 59 but under circumstances wherein the breastof the prospective wearer forming the original of the male, permanentmold has been adjusted by some suitable means to a position which it isdesigned to occupy similar to that illustrated in Figure 18. This is theuplifted position the breast will have when the uplift or pad is beingworn.

The cavity mold and male mold may then be applied together in a mannersimilar to that shown in Figure 14, but on this occasion the male moldpart will be shifted into contact with one side of the mold cavity. Onthis occasion, also, it will be appreciated that the mold cavity will besubstantially the same depth as the male mold part so that the nippleportion of the male mold will coincide with the nipple portion of themold cavity. Consequently, there will remain a space on the side of themold cavity opposite the side of contact of the mold parts which issomewhat arcuate in shape and which excludes any means for molding anipple. A bust pad 80 formed by this process will have a shape similarto that shown in Figure 18, and when attached by means of a suitablestrip 8i to a brassiere may be worn as an uplift in the manner shown.Other and simpler means, however, may be employed to fabricate the lastdescribed style of uplift pad.

In the last described form the line and contour of the portion of thepad 80 where it comes into contact with the line of junction between.the bust and breast of the prospective wearer will have the samepectoral muscle-engaging effect when worn, in addition to providing asuitable support and enhancing the appearance of the original portion ofthe breast which can be permitted to be exposed above the pad. Ends 82will extend around and conform to the sides of the breast and providecontact support at all areas.

Among outstanding applications of the method and product described isthe reproduction of an artificial breast to take the place of anamputated member. From the remaining breast, for example, an exteriorpattern may be made in reverse to form the exterior or the cavity of amold. The chest at the amputated portion forms a model for the interioror male part of the mold, and the artificial breast cast therefrom willneatly fit upon the chest and balance the breast on the other side. Abuilt-up exterior, of course, may be provided if desired.

By the provision in the manner described of false breasts which have therealistic appearance of an original breastof shapely and generousproportions there has been provided a false breast front of such designand manufacture that it can be quickly and inexpensively made, worn withcomfort, and will provide beneficial effects for the wearer wheneverworn. The false breasts are of such realistic appearance that they willsatisfy both. the visual and sensory perceptions of even the mostdiscriminating.

Although the invention has been herein shown and described in what isconceived to be the most practical and preferred embodiment, it isrecognized that departures may be made therefrom within the scope of theinvention, which is not to be limited to the details disclosed hereinbut is to be accorded the full scope of the claims so as to embrace anyand all equivalent structures, methods and operations.

The invention having been herein described, what is claimed and soughtto be secured by Letters Patent is:

1. A breast foundation front constructed in one of a number ofconventional rated breast sizes adapted for application to the cheststructure of a female form and to extend over the breast comprising abody of substantially resilient consistency, said body comprisingexterior and interior surface portions each having initially the samefull shape for the corresponding side of the form as exhibited when inuse, said exterior surface portion including a simulated nipple at themid-portion and a rim, said interior surface portion having the shape ofa breast pocket and having an irregular rim, said exterior and interiorsurface portions being matched with respect to each other so that thebody portion between them is thicker near the deepest portion of thepocket and has a progressively diminishing thickness toward the rims andforming thereby a tapered junction between said surfaceportions at saidrims having a shape and depth of contour corresponding to the shape anddepth of contour of a line of demarcation between the breast and thechest of the female form, said body on the interior side of the junctioncomprising a substantially flat area adapted in use to lie fiat againstthe chest in a position surrounding the breast.

2. A breast foundation front constructed in one of a number ofconventional rated breast sizes adapted for application to the cheststructure of a female form and to extend over the breast comprising abody of substantially homogeneous light spongy resilient consistency,said body comprising exterior and interior surface portions of skin-liketexture each having initially the same full shape for a correspondingside of the form as exhibited when in use, said exterior surface portionincluding a simulated nipple at the mid-portion and a rim of irregularconfiguration having a shape and depth of contour corresponding to thenatural shape and depth of contour at a line of demarcation between thebreast and the chest of the female form on the corresponding side of theform, said interior surface portion having the shape of a pocket notsmaller in size and proportions than' the rated breast size of the frontand having an irregular rim, said pocket having a nipple recess at thedeepest portion thereof in axial alignment with said simulated nipple,said exterior and interior surface portions being matched with respectto each other so that the body portion between them is thicker near thedeepest portion of the pocket and has a progressively diminishingthickness on all sides toward the rims and forming thereby a taperedjunction between said surface portions at said rims, said body on theinterior side of the junction comprising a substantially fiat areaadapted in use to lie fiat against the chest in a position surroundingthe breast.

JAMES P. BORDNER.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 968,272 Sextone Aug. 23, 1910996,783 Moreau July 4, 1911 2,041,066 Howard May 19, 1936 2,191,545Schneider Feb. 27, 1940 2,289,679 Porter July 14, 1942 2,342,076Herbener Feb. 15, 1944 2,391,417 Hill Dec. 25, 1945 FOREIGN PATENTSNumber Country Date 521,238 Great Britain May 16, 1940- 716,653 FranceOct. 12, 1931

